ppt and documantation

1. International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013)
794
Efficiency Improvements in Transformers by Adoption of
New Magnetic Material
Ravi Kumar Vaishya1
, Shalini Vaishya2
& S.K. Bajpai3
1
B.E., M. Tech. (Energy Technology), Jabalpur, India
2
B.E., M. E. Astt. Prof. in Dept. of Elect. Engg. GGITS, Jabalpur, India
3
B.E., M. E. Prof. & Head Energy Tech. & Dept. of Elect. Engg. GGITS, Jabalpur, India
Abstract: Since independence in India there has always
been shortage of electricity and at no point of time we have
been able to meet the peak demand. The gap between the
demand and generation can be bridged/ minimized by
either improving the installed capacity or reducing the
consumer demand. The gap between availability & demand
is of order 6% as on date. If we take into account the issues
like environment pollution and global warming, the
preferred option is to increase the energy efficiency or
minimize the consumer demand, as in the other alternative
particularly in India where thermal generation dominates
increased environmental pollution is inevitable[1].
The paper covers design of transformer using a new
technology superior magnetic material with thin sheets of
lazer grade or amorphous core. Iron Boron Silicon
amorphous alloy is a unique alloy whose structure of metal
atoms occurs in random patters as opposed to conventional
CRGO steel which has an organized crystalline structure.
The paper covers design of distribution transformer using
conventional material and the new technology improved
core materials.
The reflection on the no-load and load losses due to
change in the material have been worked out. Commercial
and technical feasibility for adoption of new technology core
material has been detailed out and the payback period is
quite attractive. By reducing the regular occurred power
loss in the transformer, economy of the power sector and
global environmental impact can be improved.[8]
The paper also covers the working of quantum of
electrical power that can be saved if adopted in the state of
M.P. The reduced Electrical Power generation
requirements due to lower losses have also been translated
to reduction in the CO2 emissions polluting the
environment.
Keywords-- Core, Copper, Tank, Steel Radiator,
Transformer Oil, Power Factor, Losses, Load Factor,
Insulation Material. ,CRGO, Lazer Grade, Amorphous
core
I. DEFINITION OF THE PROBLEM
The demand for electricity in India is enormous and is
growing steadily. This growth has been slower than
country’s economic growth. To balance this demand and
supply of electricity, it is the time to go for improvement
in energy efficiency electrical equipment in use by the
utilities and also by the consumers. Ways to improve
energy efficiency of one of the electrical equipment used
by utilities has been discussed in coming pages.
The power plant generates electricity at low voltage
rating and the generated power has to be transmitted
through long transmission line at extra high voltage i.e.
440, 220 & 132 KV to reduce the line losses and
conductor size . This extra high voltage power is then
stepped down to the desired voltage which is then used in
the industrial, commercial, transportation & domestic
sectors.
The voltage in the entire system can only be step up &
down by using transformers of different capacity. The
power passes through the transformers involving
transformer losses i.e. no-load and load losses.
These transformer losses impose heavy financial
losses and impact the environment globally. By reducing
these losses in the transformer, economy of the power
sector and global environmental impact can be improved.
[2]
Thus our objective is to design the energy efficient
transformer which reduces the total transformer loss by
60%.
II. ENERGY EFFICIENT TRANSFORMERS
No – load loss resulted from the magnetization of core
laminations, depends upon the following parameters of
core: -
1) Thickness varies from 0.23 to 3.0 mm
2) Quality - CRGO , HI-B Grade, Lazer Grade,
Amorphous
3) Flux density
4) Specific gravity of core
Reduction in No-load losses can be achieved by
1) Using better quality core
2) Sharpening the edges of the core at with appropriate
angle
3) Building Single strip core building for reduced the
air gap.
4) Annealing the core so as to
i. Reduce mechanical stress in the lamination to a
minimum to yield optimum magnetic proprieties
ii. Prevent contamination of the steel with oxygen
and or carbon
iii. Retain or enhance the insulation quality of the
lamination coating.

2. International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013)
795
Iron Boron Silicon amorphous alloy is a unique alloy
whose structure of metal atoms occurs in random patters
as opposed to conventional CRGO steel which has an
organized crystalline structure. The higher resistance to
magnetization and demagnetization through the
crystalline structure leads to higher core losses in CRGO.
Load loss of transformer depends on the load on the
transformer. [6]
1) Load Current (I)
2) Resistance of the Wire and strips used to construct the
coils.
3) Gap between Cores - Coil with tank.
Reduction in load losses can be achieved by
1 Using higher size of the conductor.
2 Reducing size of core
3 Reducing Winding Temperature.
4 Improving conductor resistivity.
5 Annealing of Wires & Strips for better performance
and life of the transformer as it
• Improve the machine-ability
• Obtain grain size and produce uniformity.
• Increase activity of metal
• Modify and improve electric & magnetic
properties.
• Release internal stresses
• Help to produce a definite micro structure
III. DESIGN OF ENERGY EFFICIENT TRANSFORMERS
1. Cost Benefit
For techno commercial study a practical size of 200
KVA,11/0.433KV distribution transformer has been
considered. For comparison purpose 200KVA
distribution has been designed using three different core
materials CRGO M-4,HiB and lazer grade stampings.
The thickness of stampings in case of M-4 and HiB
grades has been taken as 0.27mm & that of lazer grade as
0.23mm based on availability of these core materials in
the market. The working flux density before approaching
the Knee point in case of all the materials and also watt
loss/Kg are different .This amounts to that the weight of
the core and also losses particularly iron losses are going
to be different when designed considering these three
cores. Transformers with three cores under consideration
have been designed and weight of core, iron losses 7 also
load losses have been detailed out in table –I. Due to
variation in total weight of transformers and due to
variation in the rate of different cores, the initial cost of
the transformers for the three designs works out to be
different as indicated in table-I. Here it is pertinate that
the initial cost alone cannot be taken for ensuring
commercial viability but we need to take into account the
variation in the iron and load losses as well.
In case we consider/assume
i. Rate of interest (@ 10 %)
ii. rate of electrical energy as Rs 3/kwh
iii. life of transformer (as 25 years)
iv. Load factor of distribution transformer as 60%
The iron and copper losses can be capitalized for
working out the commercial feasibility. The capitalized
cost of iron losses (Wi),Copper losses (Wc) and total cost
(Ct) including initial cost as worked out as indicated in
table-I
A 200 KVA 11/0.433 KV Transformer with different
three core materials:
Table -1
Parameters Conven. EET I EET II
Core material CRGO M-4 HiB Lazer
Grade
Thickness 0.27 0.27 0.23
Watt/Kg 1 0.56 0.3
Weight of
core
396Kg 457Kg 465Kg
Iron Losses 500 Watts 300 Watts 180 Watts
Load Losses 2800 Watts 2300
Watts
2300 Watts
Initial Cost 200000 230000 260000
Wi 119272 71563 42938
Wc 291979 243316 243316
Ct 611251 544879 546254
Saving per transformer 66372 64997
Saving in respect of KW
Total Saving in Losses = 0.82 KW
Number of Transformer required to save one number 25
KVA transformer will be 25/0.82 = 30 nos.
Thus for every 30 installation of 200 KVA EET, one
number 25 KVA transformer will be saved.[10]
Case OF MP State Utility
The total installed distribution transformers in M.P.
state as on feb 2012 are [15]:

3. International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013)
796
Table -2
MP Distribution
companies
Capacity
in
KVA(a)
East
zone
Central
zone
We
st
zon
e
Total(b) KVA(axb)
16KVA 3927 375 575
6
10058 160928
25KVA 17797 26603 698
1
51381 1284525
63KVA 23177 30893 312
22
85292 5373396
100KVA 18467 21740 364
90
76697 7669700
200KVA 5426 9457 121
01
26984 5396800
19885345
CALCULATION OF ENERGY SAVING IN MWH: -
Energy saving by Energy Efficient 200 KVA
Transformer = 0.82 KW per hour
Thus saving for 1 KVA = (0.82 / 200) KWh
Net saving by replacing entire transformers of the
system will be
19885345 * 0.82 / 200 KWh = 81530 KWh
≈ 81.5 MW per hour
2. Environmental benefit
• The heat dissipation by the Tank Surface &
Radiators can be reduced by designing better energy
efficient transformer thus will be beneficial to the
global environment.
• This reduction in the heat dissipation will improves
the life of insulations of the core, oil & winding and
thus save the wastage in the form of burning or
heating.
• For every 25 installation of 200 KVA Energy
Efficient transformer, one number 25 KVA
transformer will be saved thus this will save natural
resources, metal & alloy, conversion & processing
energy.
• Since Generation of power lost in terms of
transformer losses will be reduce, the emission of
CO2 will be reduced.[12]
Calculation of co2 emission reduction: -
60 W of electricity emits Co2 @ 60 grams/hr[14]
i.e. 1 W will emit Co2 @ 1 gram /hr
thus, 81530000 W will emit Co2 81530000 grams /hour
i.e. 81530 Kg / hour Co2 emission will be reduced in the
environment.
Calculation of reduction in coal consumption: -
Coal require to generate 1 unit i.e. 1KWh = 0.75 Kg
Coal require to generate 81530KWh = 81530 * 0.75
= 61148 Kg / h
i.e. coal require in a year will be 61148 * 24 * 365 =
535656480 Kg / yr
Net Saving in Coal Consumption will be 535657 Tons
per year
III. ELECTRICAL UTILITY BENEFITS
A. Demand side management
Installation of our design energy efficient transformer
will help in improving the demand side management
since the power lost in the form of transformer losses will
be reduced and more power can be delivered from the
same capacity of transformer in the distribution system.
B. Reduction in the rate of failure
The agricultural consumers imposes load more than
100% of the capacity of the transformer which is
uncontrolled during the Rabi Season. The maximum
failure of the transformer occurred during this season in
the rural areas.
Energy efficient transformer will help in reducing rate
of failure in normal course and in Rabi season since
1. The core of our designed transformer will saturate
on 125% loading and conductor is designed with
relatively lower current density to bear additional
current and thus 25 % additional loading can be
sustain by this transformer.
2. Since the heat dissipation of the transformer is
reduced, the life of insulation in the core, oil &
windings will be improved which reduces the
failure of the transformers.
3. The reduction in the winding temperature will
reduce the resistance of the coil which in turn
reduces the load losses.
4. The losses of Energy Efficient Transformer will be
reduced as compare to the conventional transformer
and thus the generation of saved power will be
reduced and this will save generation as well as the
consumption of fossil fuel and emission of harmful
gases in the environment.
IV. CONCLUSION
There is enormous potential for saving energy and
increasing efficiency by employing these transformers,
and paper intends to promote higher standards to govern
their use. There is also potential for improvements
through capacity building with manufacturers and the
end-users.

4. International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 3, Issue 3, March 2013)
797
In this paper design of transformer is carried out to
find the better quality core to reduce the losses and
improve the efficiency of the transformer as well as
entire transmission & distribution system for a greener
future. Since independence there is power shortage of
Electrical energy & despite all out efforts by state/Central
government we have not been able to meet the electrical
energy demand .The gap between availability & demand
is of order 6% as on date. The proposed low loss
transformer will bridge the gap between supply &
demand. Since the reduction will be at the load end, it is
for more beneficial than adding at generation side.
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[15 ] www.mppmcl.com